Footwear suspension system

ABSTRACT

Footwear includes an upper, an outsole attached to a lower portion of the upper; and a sock liner disposed within to the upper and attached to a region of the upper above a bottom portion of the sock liner, the sock liner having a heel portion spaced above a top surface of the outsole, the sock liner attached to the upper

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional application No. 60/986,074, filed Nov. 7, 2007, and entitled “Footwear Suspension System,” which is incorporated herein by reference.

BACKGROUND

This invention relates to footwear.

Each year two out of three runners are sidelined by a running related injury. The injuries are caused by cumulative micro-trauma caused by repetitive impact experienced during running. A runner's heel strike generates a force that can equal as 2.5 times body weight at the foot and as much as seven times body weight at the hip. For several decades, footwear manufacturers have sought to alleviate detrimental heel strike through changes in running shoe design. This mission brought about the cushioning trend in running footwear. The idea was that a cushioning midsole will respond to impact by absorbing and storing some of the impact force as elastic energy. Unfortunately, the cushioned midsole of the modern running shoe deprives the system of important sensory information necessary for ankle, knee, and hip response to impact. The arch support (or “orthotic”) in modern running shoes prevents the arch suspension system from absorbing energy by averting flattening. Current arch support systems can eventually lead to intrinsic muscle atrophy and complete loss of active muscular control. These problems require a progressive shift in running shoe design and technology.

Not only are runners commonly plagued with persisting injuries, they also have to deal with a consistent monetary investment for shoe upkeep. A typical maintenance problem is the rapid deterioration of running shoe outsoles. Having to replace an entire shoe when only one portion is faulty is a waste of money. In addition, significant environmental problems are attributed to overactive consumer consumption and the subsequent excessive waste.

SUMMARY

In a general aspect of the invention, footwear comprises an upper, an outsole attached to a lower portion of the upper; and a sock liner disposed within to the upper and attached to a region of the upper above a bottom portion of the sock liner, the sock liner having a heel portion spaced above a top surface of the outsole, the sock liner attached to the upper.

Embodiments of this aspect of the invention may include one or more of the following features. The upper is formed of injection-molded plastic. The sock liner is formed of a mesh and possibly over-molded sections of additional injection molded plastic. The footwear further comprises replaceable pods attached to a bottom surface of the outsole. The replaceable pods include layers of different colors. The footwear further comprises replaceable cleats configured to be attached to the lower portion of the upper or to a bottom surface of the outsole.

In a particular embodiment of the footwear, the footwear comprises a shock absorber including a base shank attached to an upper surface of the outsole; and a side shank integrally attached to the base shank and a side region of the upper. In this embodiment, the footwear can further include a plurality of shock absorbers each having a different stiffness characteristic.

In another embodiment, the footwear further comprises an adjustable shock absorber including a post attached positioned between the outsole and the upper; a resilient member attached to the post; and a regulator (e.g., a rotatable knob) configured to adjust the level of resilience of the resilient member. The resilient member can be a coiled spring surrounding the post.

In still another embodiment, the footwear further comprises a shock absorber including a back strip attached between the outsole and an upper region of the upper; at least one stiffening band attached to a surface of the back strip; and a regulator configured to adjust the level of stiffness of the at least one stiffening band. In certain embodiments, the footwear includes a plurality of back strips, each including at least one stiffening band attached to a surface of a corresponding one of the back strips and a regulator (e.g., a rotatable knob), one of the plurality of back strips attached to a first side region of the upper and another one of the plurality of back strips attached to a second side region, opposite the first side region of the upper.

Currently available running shoes use compression technology that is based on the hardness or the design of injected material (e.g., ethylene vinyl acetate “EVA”). The problem with the present technology is that it cannot adapt to the individual characteristics of the runner. Among other advantages, the footwear described above, accommodates the various weights and sizes of wearers (e.g., runners) by providing differing degrees of shock absorption necessary for varying weight, cant, and comfort. Absorption adjustment can be made for up and downward forces and side to side roll. In addition, pronation can be remedied by adjusting the shoe to cushion one side of the heel versus the other. The injection molding process allows for an efficient shoe design as well as a reduction in off-shore dependence in specialty manufacturing (as this is a process that can be fully completed closer to any point of sales). The on-shore production of the footwear also serves to enhance the secondary goal of environmental consciousness by reducing energy dispelled by long distance transportation. The ecological mission is furthered by the use of recyclable materials which will conserve energy, material, and costs. Additionally, the use of replaceable pods that are secured to the outsole will increase the life of the shoe and will alleviate the amount of landfill waste created by shoes prematurely discarded.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a perspective view of shoe having a suspended sock.

FIG. 2 shows an exploded view of the shoe of FIG. 1.

FIG. 3 is a cross-sectional rear view of the show of FIG. 1 showing the “Tupperware” like seal.

FIGS. 4A and 4B illustrate the shoe in use in a relaxed and compressed state, respectively.

FIG. 5 is a bottom view of the shoe of FIG. 1 showing replaceable outsole pods.

FIG. 6 is a side view of the shoe of FIG. 1 describing the process for assembling the replaceable outsole pods of FIG. 6.

FIG. 7 is a flowchart describing the process for assembling the shoe of FIG. 1.

FIG. 8 is a perspective view of another embodiment of a shoe having an adjustable shock absorber.

FIG. 8 a is a cross-sectional side views of the heel portion of the shoe of FIG. 8 in a relaxed state.

FIG. 8 b is a cross-sectional side views of the heel portion of the shoe of FIG. 8 in a compressed state.

FIG. 9 is a perspective view of another embodiment of a shoe having an adjustable shock absorber.

FIG. 9 a is a cross-sectional side views of the heel portion of the shoe of FIG. 9 in a relaxed state.

FIG. 9 b is a cross-sectional side views of the heel portion of the shoe of FIG. 9 in a compressed state.

FIG. 10 is a perspective view of another embodiment of a shoe having an adjustable shock absorber.

FIG. 10 a is a cross-sectional side view of the heel portion of the shoe of FIG. 10 in a relaxed state.

FIG. 10B is a cross-sectional side view of the heel portion of the shoe of FIG. 10.

FIG. 11A is a bottom view of an embodiment of a shoe having replaceable cleats.

FIG. 11B is a side view of the shoe of FIG. 11A showing replaceable cleats.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a running shoe 100 includes a sock liner 200, an upper 202, and an outsole assembly 204. The shoe is assembled such that the sock liner 200 is inserted into the upper 202 which is placed onto the outsole assembly 204. The sock liner 200 is composed of a mesh encasement 206 with an injection molded insole 208 at the base, an upper support member 210 that surrounds an opening 211 where a wearer inserts her foot, a rear support member 212 that runs vertically along the back of the mesh encasement 206 to connect the insole 208 to the upper support member 210, and an inner lacing support member 214 on the top. Below the lacing support member 214 is a tongue 104 that stabilizes the shoe on the foot. The lacing support member 214 includes holes 218 on either side of tongue 104 into which a shoelace 102 can be woven. The mesh encasement 206 is made of a durable, self-adjusting material. In alternative embodiments, the mesh can include over-molded sections of additional injection molded plastic. The mesh 206 slackens where parts of the foot need give, while simultaneously tightening around the areas that need support. This feature will be particularly beneficial to the navicular bone, one of the tarsal bones of the foot. Most of the impingement force caused by foot strike is focused at the central one third of the navicular bone, and if this pressure is not braced, can lead to a fracture or a more serious injury.

The sock liner 200 is inserted into the upper 202 such that it is attached to the upper 202 at a front region 219 and such that a heel portion 221 is suspended above the upper 202. As will be discussed in greater detail below, this suspension design provides shock absorption of differing degrees suitable for various runners' weights and running conditions, and provides shock absorption for upward, downward, and side-to-side forces. The upper 202 includes a frame 222 with a base 224 that connects to the outsole assembly 204, an opening 226 where the wearer inserts her foot (corresponding to the location of the opening 211 in the sock liner 200), and an outer lacing support member 228. The outer lacing support member 228 has an array of holes 220 that align with the holes 218 in the sock liner 200 to be used with a shoelace 102. Both the right side and the left side of the frame 222 include rear ventilation holes 232, middle ventilation holes 234, and side front ventilation holes 236 for ventilating the foot. The frame 222 also contains a single ventilation hole 238 for the same purpose. The base 224 of the upper 202 also contains several holes 240 which are used to connect the upper 202 to the outsole assembly 204. The outsole assembly 204 includes a rear outsole pod 242 and the front outsole pod 244. Both the rear outsole pod 242 and the front outsole pod 244 contact the ground and include fastening features 248 for securely fastening the outsole assembly 204 to the bottom of upper 202.

Referring to FIG. 3, the rear heel portion of running shoe 100 includes the upper support member 210 being attached to the frame 222 of the outer lacing support member 228. Upper support member 210 is attached to frame 222 with a rim-seal where the rim of frame 222 is secured between integral walls 213 of upper support member 210. This rim-seal is similar to that found with Tupperware® plastic containers. The heel portion 221 is created by a mesh encasement for the foot 212 being suspended from the upper support member 210. The outsole 246 is attached to the frame 222 by the fastening members 248.

Referring more particularly to FIGS. 4 a and 4 b, when the shoe is in use, the rear heel portion 221 softens the runner's landing by receiving the downward force placed upon the frame 222 of the upper, rear outsole 242, front outsole 244, and the outsole pods 246 and deflecting those forces outwardly to the sides of the frame 222. This deflection is possible due to the absence of a heel strike area. The heel portion 221 of the sock liner's insole 208 remains suspended upon impact, therefore causing the strike force to radiate outwardly to the side periphery.

Referring to FIG. 5, the bottom of the frame 222 and specifically the holes 240 formed within frame 220 receive the fastening features 248 that receive the front pod 244 and rear outsole pod 242. The fastening features securely lock into the bottom of the shoe yet maintain the ability to be detachable. Outsoles of traditional running shoes wear down differently depending upon the running style of the individual. For example if a runner is an overpronator (i.e. a runner with a overly inward roll of the foot and in particular the heel and arch which occurs naturally at the heel strike as a cushioning mechanism) they will strike the outsides of their outsoles with more force, which result in specific deterioration of those regions. All traditional running shoe features are intrinsically linked, which means that when one part is faulty it affects the entire shoe. Running shoe 100 minimizes this problem by using replaceable front outsole pod 244 and rear pod outsole 246. 244, 246 will also correct overpronation and supination (also known as underpronation, is the opposite of pronation, where the feet don't roll inward enough. Wearing the wrong type of shoe will lead to painful shins and joints, or even injury) for the runner will be able to customize the pods by purchasing versions with various thicknesses. The pods can also be modified for different weather and terrains. Harder compounds will be available for asphalt, as well as soft compounds for rubber tracks, textured cement, and other surfaces. A studded version is an option for increased traction in inclement winter conditions.

Referring to FIG. 6, both the front outsole pod 244 and the rear outsole pod 242 lock into place by snapping into holes 240 for connection with outsole assembly 204. When this process is complete the fastening features 248 will be secured into the holes 240 for connection with outsole assembly 204, and the outsole 246 will be exposed to the ground surface. As these pods wear down through use, instructive color sections will appear. For example, each pod is black and with wear turns yellow and then finally red, which indicates the need for replacement. With this color coded system, the runner is able to replace select parts, thus extending the longevity of the running shoe 100.

Referring to FIGS. 11 a and 11 b, in another embodiment, the bottom of frame 222 contains holes 260 for receiving cleats 262. Each cleat 262 is formed of a base 264 and a stem 266. Stem 266 is screwed into or otherwise attached to a receiving portion 267 of hole 260 such that cleat 262 protrudes below the bottom of frame 222. Large cleats 268 and small cleats 270 may be used at various positions on the bottom of frame 222 depending on the desired effect (e.g., increased traction, minimize wear to frame or outsole). The cleats 262 may be added and removed as necessary. Alternatively, an outsole (not shown) may be attached to the bottom of frame 222 and cleats 262 may be attached to the outsole.

Referring to FIG. 7, the process for constructing shoe 100 includes creating frame 222 using injection molded technology (702). The flexible fiber inner sock liner 200 is knitted/weaved (704). Outsole assembly 204 including outsole pods 242, 244 is formed by compression molding using, in this embodiment, three layers of colored rubber (706). The sock liner 200 supportive elements are then over-injected molded to the sock liner 200 (708). The injection molded edge of the sock liner 200 is then clipped onto the corresponding edge of the plastic frame 222 (710). Outsole pods 242, 242 are attached to the injection molded frame 222 (712). Laces 102 are then threaded through the holes provided in the sock liner 200 and frame 222 to join the parts (714).

Referring to FIG. 8, another embodiment of a running shoe includes an adjustable shock absorber for further providing additional comfort and support for the shoe wearer (e.g., a runner). For example, in this embodiment, a shank shock absorber 300 attaches to the shoe structure through two regions, a side shank attachment 306 and a base shank attachment 308. The shank structure 300 is formed with injection molded plastic, and can be made into three models of varying stiffness: soft, medium, and hard. These levels of stiffness will correspond to the runner's specific weight class. While in use, the integral shank 300 bends under the added weight and thereby increases stiffness which stores heel strike energy for the runner. The side shank attachment 306, includes a hole 312 that locks onto a fastening button 250 featured on the side of the frame 222. The base shank attachment 308 has additional support with the base shank fasteners 310.

Referring to FIG. 8 a, the running shoe with the shank shock absorber 300 is shown in a state of relaxation. In this state the shank shock absorber 300, and in particular, the side shank attachment 306 has a relatively low level of stress and remains in its original positioning.

Referring now to FIG. 8 b, running shoe with shank shock absorber 300 is shown in a state of downward forcing compression. With the additional pressure, the sock liner 200, particularly the injection molded heel portion 221, gains proximity to the outsole assembly 204 and the base shank attachments 308. The side shank attachment 306 adjusts to the increased weight and bends to accommodate the frame 222 and the sock liner 206. This movement by the side shank attachment 306 serves to provide heel strike support to the runner. By providing a stable landing, injuries are less likely to occur. Additional benefits include increased propulsion from heel strike, which gives the runner a more enhanced performance.

Referring to FIG. 9, a further embodiment of running shoe is shown with a dual adjustable shock absorber 302. The dual adjustable shock absorber 302 is permanently attached to the posterior of the frame 222 and includes a threaded post 318 positioned through a coiled spring 316. A dial 314 and the coiled spring 316 are attached to the threaded post 318. The threaded post 318 is located between the injection molded frame 222 and the outsole assembly 204. The dial 314 is provided at the upper end of threaded post 318 and is used to adjust the amount of tension held by spring 316. By turning the dial 314, the spring 316 is compressed upon the threaded post 318, which reduces the distance between the coils of the spring 316 and increases the overall shock resistance of the shock absorber 302. The benefit of having a dual adjustable shock absorber 302 is the ability to adjust both sides or just one side of the shoe 100. By adjusting one side of the dual adjustable shock absorber 302, one can alter the cant of the shoe. This provides a direct way to aid with addressing over-pronation and supination by adjusting the shoe to cushion one side of the heel versus the other.

Referring to FIG. 9 a, the running shoe with the dual adjustable shock absorber 302 is shown in a state of relaxation. In this condition, the shoe does not experience compression with the sole pressure being put on the spring applied by the positioning of the adjustable dial 314.

Referring to FIG. 9 b, the running shoe with dual adjustable shock absorber 302 is shown in a state of downward-forcing compression. The additional pressure forces the spring coils of spring 316 to compress upon the threading rod 318, while the sock liner 200, particularly the injection molded heel portion 221, is moved closer to the outsole assembly 204.

Referring to FIG. 10, still a further embodiment of a running shoe having an adjustable shock absorber option includes a dual adjustable blade suspension 304. In this embodiment, the heel portion of the shoe is exposed by side openings 328 and back openings 330 in the frame 222. Openings 328, 330 leave two vertical back strips of the frame 322 on either side of the heel area. The back strips 322 are slightly concave to accommodate the sock liner 200 and the runner's foot when inserted into the shoe. On the inside of the back strips 322 are two individual stiffening bands 324 that are secured into the back frame 322 by upper and lower barriers 332. The stiffening bands 324 are also attached to the main shoe frame 222 by a support pin 326 which links to a corresponding adjustable dial 320 attached to each back strip 322. Each dial 320 is used to either loosen or tighten the stiffening bands 324. At the tightest setting of dial 320, the stiffening bands 324 are flush against the back strips 322, which will provide the runner with the highest level of stiffness; thus being the most shock resistant. At the loosest setting of dial 320, stiffening bands 324 will remain moderately slack and will be spaced away from the back strips 322. This placement will offer maximum compression and the least shock resistance.

Referring to FIG. 10 a, the running shoe with the dual adjustable blade suspension 304 is shown in a state of relaxation. At this low level of stress, the only pressure applied to the suspension system is the tension of the stiffening bands 324 controlled by the adjustable dial 320.

Referring to FIG. 10 b, the running shoe with dual adjustable blade suspension in a state of compression. This additional impact will apply pressure on the back strips 322 as well as the stiffening bands 324 causing them to flex outwards. The stiffening bands 324 will provide optimal shock absorption for whatever level of tension the runner chooses.

It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments are within the scope of the following claims. 

1. Footwear comprising: an upper; an outsole attached to a lower portion of the upper; and a sock liner disposed within to the upper and attached to a region of the upper above a bottom portion of the sock liner, the sock liner having a heel portion spaced above a top surface of the outsole, the sock liner attached to the upper.
 2. The footwear of claim 1 wherein the upper is formed of injection-molded plastic.
 3. The footwear of claim 1 wherein the sock liner includes a mesh.
 4. The footwear of claim 1 wherein the sock liner includes over-molded injection molded plastic.
 5. The footwear of claim 1 further comprising replaceable pods attached to a bottom surface of the outsole.
 6. The footwear of claim 5 wherein the replaceable pods include layers of different colors.
 7. The footwear of claim 1 further comprising a shock absorber including: a base shank attached to an upper surface of the outsole; and a side shank integrally attached to the base shank and a side region of the upper.
 8. The footwear of claim 1 further comprising a plurality of shock absorbers each having a different stiffness characteristic.
 9. The footwear of claim 5 further comprising an adjustable shock absorber including: a post attached positioned between the outsole and the upper; a resilient member attached to the post; a regulator configured to adjust the level of resilience of the resilient member.
 10. The footwear of claim 9 wherein the regulator includes a rotatable knob.
 11. The footwear of claim 9 wherein the resilient member is a coiled spring surrounding the post.
 12. The footwear of claim 1 further comprising a shock absorber including: a back strip attached between the outsole and an upper region of the upper; and at least one stiffening band attached to a surface of the back strip; and a regulator configured to adjust the level of stiffness of the at least one stiffening band.
 13. The footwear of claim 1 further comprising a plurality of back strips, each including at least one stiffening band attached to a surface of a corresponding one of the back strips and a regulator, one of the plurality of back strips attached to a first side region of the upper and another one of the plurality of back strips attached to a second side region, opposite the first side region of the upper.
 14. The footwear of claim 12 wherein the regulator includes a rotatable knob.
 15. The footwear of claim 1 further comprising replaceable cleats configured to be attached to the lower portion of the upper.
 16. The footwear of claim 1 further comprising replaceable cleats configured to be attached to a bottom surface of the outsole. 